Table 6: Cumulative Yearly savings across 5 part numbers
operation. The downstream effects of this are clear: a skilled workforce can lead to even greater gains in efficiency and consistency.
Environmental and Sustainability Impact Reducing waste and energy consumption were central goals in this study, and we saw significant strides in both areas. The drop in scrap, along with the savings in wax, shell material, and metal, directly contributes to a more sustainable manufacturing process. Fewer defective parts mean less material wasted, less energy used to rework or recycle parts, and a smaller overall environmental footprint. These are not just operational
improvements—they align with the broader sustainability goals that many of us in manufacturing are striving to meet. Saving shell material and metal (by reducing the number of Assemblies) doesn’t just cut costs—it reduces the demand on raw materials, energy, and waste management. In an era where manufacturers are under increasing pressure to minimize their environmental impact, these results show how modernizing the wax room can be a critical part of that effort.
Future Opportunities for Improvement Looking ahead, there are several areas where we can push the envelope even further. One of the biggest opportunities is in automating downstream processes like cutoff and shell cleaning. We’ve
®
already seen gains here due to better consistency, but full automation could eliminate manual errors altogether and drive even more efficiency.
Another area to explore is the potential for optimizing smaller batch sizes. The flexibility offered by automation means we can handle low- volume runs with the same efficiency as high-volume production. As customer demand for flexibility grows, this could be a significant competitive advantage. Finally, I see a lot of potential in reducing the number of shell coats required due to increased strength from bridging. If we can optimize this further, we could see reductions in material usage and production time, which would amplify the gains we’ve already achieved.
Conclusion The results of this study show that automation and process optimization in the wax room lead to real, measurable improvements. We’ve seen gains in production capacity, material savings, and labour efficiency. More importantly, we’ve proven that these improvements align with our goals of sustainability and lean manufacturing. By reducing waste, cutting energy use, and upskilling our workforce, we’re building a more efficient and resilient operation. These findings lay the groundwork for future advancements. automation,
With we’re not just making
incremental changes—we’re laying the foundation for a more flexible,
February 2025 ❘ 29
sustainable, and scalable manufacturing process. The gains we’ve seen here are just the beginning. As technology evolves, we’ll continue to push forward, finding new ways to optimize every part of the process.
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40
